Portion controlled frozen food

ABSTRACT

The specification discloses a system and process for producing discrete chilled products having preselected weights from a semi-fluid mixture. The semi-fluid mixture is pumped along a distribution path to an extrusion manifold which extrudes a continuous sheet of the mixture. The continuous sheet is directed through a chilling station where it is chilled and firmed such that the sheet maintains its extruded cross-sectional configuration. A plurality of slicers continuously slice the continuous sheet of material into continuous lengths. A cutter periodically severs the continuous lengths at predetermined intervals to provide a plurality of discrete products having predetermined weights. The pumping rate, rate of travel through the freezer and periodic severing of the continuous lengths may be selectively varied in order to maintain any desired weight of the discrete products. In an alternative embodiment, the continuous sheet of material is divided into discrete products by stamping the sheet with a plurality of cutters. In another embodiment, a rotatable cutting drum, having a plurality of equally spaced circumferential slicing disks and equally spaced longitudinal blades, severs the continuous sheet of material into discrete products.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of Ser. No.526,146, now abandoned, filed Nov. 22, 1974 by the present applicant andentitled "PORTION CONTROLLED FROZEN FOOD".

FIELD OF THE INVENTION

This invention relates to the preparation of discrete frozen products,and more particularly relates to a system and method for producingfrozen foods in individual discrete portions.

DESCRIPTION OF THE PRIOR ART

A wide variety of products, such as explosives, rubber devices, foodproducts and building materials are commonly formed from a semi-fluidmaterial. When the semi-fluid material is not sufficiently rigid tomaintain its shape after extrusion, it has been heretofore quitedifficult to form discrete products having a predetermined shape andhaving a desired weight. It has thus been common to prepare discreteproducts from semi-fluid material by filling individual containers ormolds and then freezing or otherwise treating the individual containers.Such processes requiring the filling of individual containers have beenfound to be relatively slow and expensive.

With respect to food products, it has become desirable in the home,restaurants and other places to utilize food portioned in predeterminedserving sizes or portions. For example, it has become desirable toprovide serving portions of sausage such as a one-ounce sausage link ora two-ounce sausage patty. However, it has not heretofore been practicalto provide such close controlled portion sizes of foods such as skinlesspork sausage with conventional packaging techniques.

It has heretofore been known to produce skinless sausage of varioustypes by stuffing comminuted meat into a casing, setting the meat bychilling or cooking and then stripping the casing from the meat. Therequirement of stuffing the casing and then stripping the casing is timeconsuming and of course wasteful. It has also reportedly been heretoforeattempted to extrude pork for various processing techniques, but theresulting friction along the sides of the extruding tube have caused fatto come to the surface of the pork, thereby producing a product whichappears to consist of all fat or excessive fat, and it is thereforeunpleasing to the consumer.

A need has thus developed for a system and process to enable thecontinuous forming of a plurality of discrete solid products fromsemi-fluid material. The system and process must not only be fast andcost effective, but must enable the formation of a plurality ofdifferent shapes and sizes of discrete products with very close weighttolerances.

SUMMARY OF THE INVENTION

The present invention has reduced or eliminated the problems associatedwith the prior art previously described. In accordance with the presentinvention, a plurality of discrete products having a predeterminedweight may be formed by a system which pumps a semi-fluid mixture alonga distribution path. An extrusion manifold receives the semi-fluidmixture and extrudes the mixture at a selected rate to form a continuoussheet of mixture having a predetermined uniform cross-section. Aconveyor directs the continuous sheet through a chilling station inorder to chill and firm the sheet such that the sheet maintains itsextruded cross-sectional configuration. Structure severs the continuoussheet into a plurality of discrete products having predeterminedweights.

In accordance with another aspect of the invention, a system is providedfor forming a plurality of discrete products having preselected weightswhich includes a hopper for receiving a quantity of warm semi-fluidmaterial. A pump pumps the material through a feed line at a selectedrate and pressure. An extrusion manifold has an inlet connected at theend of the feed line and includes an outlet with a smaller dimensionthan the inlet. A flexible conduit extends from the manifold outlet andincludes an end nozzle to form a continuous extruded sheet of material.A chilling chamber is mounted adjacent the end nozzle. A conveyorreceives the continuous sheet from the end nozzle and carries thecontinuous sheet through the chilling chamber where it is chilled andfirmed. A plurality of cutting disks are mounted at the outlet of thechilling chamber and continuously slice the sheet into continuouslengths of material. A cutting blade is movable in synchronism with theconveyor for severing the continuous lengths to form a plurality ofdiscrete products having the selected weight.

In accordance with a more specific aspect of the invention, a cuttingsystem is provided to periodically sever the sliced continuous lengthsof material and includes structure for receiving a plurality of parallellengths of material traveling in a direction parallel to the axes of thelengths. An elongated cutting blade is disposed above and normal to thedirection of travel of the lengths of material. Structure moves theblade downwardly for simultaneously severing all of the lengths ofmaterial while moving the blade in the direction of travel of thelengths of material and at the same rate of speed as the lengths ofmaterial.

In accordance with another embodiment of the invention, a plurality ofcutting molds are provided for stamping the continuous sheet as it isextruded from the end nozzle onto the conveyor to form a plurality ofdiscrete products. Each cutting mold has a cutting edge for severing apredetermined shape of chilled mixture from the continuous sheet. Avacuum is drawn above the severed shapes of mixture to permit withdrawalof the severed shapes from the continuous sheet. A second conveyor isoperable with the cutting molds whereupon the severed shapes of mixtureare deposited and carried to a packaging station.

In accordance with still another embodiment of the invention, arotatable drum is provided for severing the continuous sheet intopredetermined discrete products. The drum is adapted with equally spacedsharpened circumferential blades for slicing the sheet into continuouslengths and sharpened longitudinal blades for severing the lengths toform the predetermined shapes from the chilled mixture. The drum ispositioned to sever the continuous sheet by the action of thecircumferential and longitudinal blades against the continuous sheet asit is moved on the conveyor. The drum is rotated so that thecircumferential blades move at the same speed of travel as the linearconveyor on which the continuous sheet moves. The linear conveyor isadapted with indentions for receiving the sharpened edges of thecircumferential and longitudinal blades to facilitate cutting of thecontinuous sheet.

In accordance with yet another aspect of the invention, a process forproducing pork sausage includes boning warm pre-rigor pork. The bonedpork is then comminuted to form a semi-fluid mixture which is pumped toan extrusion location. The semi-fluid mixture is then extruded into acontinuous sheet having uniform cross-sections. The extruded continuoussheet is chilled such that it maintains the desired cross-sectionalconfiguration. The sheet is periodically severed to form a plurality ofchilled discrete sausage portions having the same weight andconsistency.

DESCRIPTION OF THE DRAWINGS

For a more detailed description of the present invention and for furtherobjects and advantages thereof, reference is now made to the followingdescription, taken in conjunction with the accompanying drawings, inwhich:

FIG. 1 is a block diagram of the present portion controlled formingsystem;

FIG. 2 is a perspective view of the extruding portion of the system;

FIG. 3 is a partially broken away view of the extrusion manifold of theinvention;

FIG. 4 is a sectional view of the extrusion manifold shown in FIG. 3taken along line 4--4;

FIG. 5 is a sectional view of the extrusion manifold shown in FIG. 3taken along line 5--5;

FIG. 6 is a perspective, partially broken away view of the extrusionnozzle assembly of the invention;

FIG. 7 is a perspective enlarged view of the nozzle connectionsassembly;

FIG. 8 is a sectional view of the extrusion material form shown in FIG.6 with a continuous sausage sheet disposed therein;

FIG. 9 is a side view of the parallelogram lift linkage for the nozzleassembly;

FIG. 10 is a perspective view of the slicing disks of the invention;

FIG. 11 is a sectional view taken along line 11--11 of FIG. 10;

FIG. 12 is a perspective, partially broken away view of the cuttingtable of the invention;

FIGS. 13a-13d illustrate the cutting operation of the blade and bed ofthe cutting table;

FIG. 14 is a perspective view of the outlet of the cutting table;

FIG. 15 is a perspective view of a second embodiment of a cutting devicefor use with the present invention;

FIG. 16 is a sectional view taken along line 16--16 of the cuttingdevice shown in FIG. 15;

FIG. 17 is a perspective view of a third embodiment of a cutting devicefor forming preselected shapes of sausage products;

FIG. 18 is a sectional view taken along line 18--18 of the cuttingdevice shown in FIG. 17; and

FIGS. 19a--19c illustrate the cutting operation of the cutting deviceshown in FIGS. 17 and 18.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 is a top flow plan illustrating the use of the present productforming invention to make fresh pork sausage. It has been found that thepresent invention is particularly adaptable to making fresh pork sausageand a detailed description of the invention will be made with respect toproduction of pork sausage from warm semi-fluid pre-rigor pork. However,it will be apparent that the present invention may also be utilized toform discrete products from other semi-fluid materials. For the purposesof this invention, the term semi-fluid is defined as material which ispumpable through conduits. The present system may thus be utilized toextrude hot or chilled ground meat, or other types of pumpable material.

Referring to FIG. 1, freshly killed hogs are dressed, skinned and cutshortly after slaughter. The still warm pre-rigor pork is cut on aboning table 10 and all cuts including the ham, loins and the like ofthe hogs are utilized in making the sausage. The hot boned meat comingoff the boning table 10 is fed into a grinder 12 and is checked for fatcontent to maintain the fat content at 35%. A fat analysis unit, notshown, is maintained near the grinder 12 in order to make rapid fatchecks regarding the fat content of the sausage being ground. The outputof the grinder 12 is applied to two blenders 14a and 14b which form thesausage into a semi-fluid fluent material which will not retain itsshape after being extruded.

In the preferred embodiment of the invention, it is necessary that thehogs be boned and ground within about four hours from slaughter beforerigor mortis, and the temperature of the boned meat be maintained at asnear body temperature as possible, and at any rate above 80° F., suchthat the rended pork output from the blenders 14a and 14b is semi-fluidso as to freely flow. The process should be carried out in a room havingan ambient temperature of not under 50° F. In the preferred embodiment,it is preferable to bone, grind, chill and sever the pork sausage within90 minutes after slaughter. Alternatively, the present system mayutilize chilled raw material which becomes semi-fluid after blending inthe blenders 14a and 14b.

In the preferred embodiment, the blenders 14a and 14b may comprise, forexample, two 3,000 pound Rietz blenders. The semi-fluid material outputfrom the blenders moves through conduit 15 and is applied through a pump16, which may comprise for example an auger feed pump including ade-aerating head. Pump 16 applies semi-fluid pork sausage through adistribution line 18 at a predetermined flow rate to an extrusionmanifold 20. Although only a single manifold 20 is illustrated, it willbe understood that two or more manifolds may be utilized, depending uponthe desired quantity of material to be handled. The manifold 20 extrudesa continuous sheet of semi-fluid material which is applied throughflexible conduit 22.

Flexible conduit 22 includes a nozzle on the end thereof to form andextrude a continuous sheet 23 of pork sausage having a predetermineduniform cross-section, the continuous sheet being moved through afreezer 24. The continuous sheet moves at 15-feet per minute throughfreezer 24, whereupon the continuous sheet is quickly chilled to anextent that it maintains its extruded cross-sectional shape. Freezer 24may comprise any suitable type of freezer, but in the preferredembodiment comprises a liquid nitrogen freezer such as the Cyro-Quickfreezer manufactured and sold by Air Products Corporation. In somecases, it may be desirable to spray a refrigerant such as nitrogen orfluorocarbon upon the sausage or on the underside of the moving conveyorbelt in order to quickly chill the sausage.

The chilled pork sausage exits freezer 24 at an internal temperature of-10° F. The chilled sausage is continuously sliced into equal widthcontinuous lengths by a slicer 25 and periodically severed into desiredlengths by a cutter 26 to form a plurality of discrete sausage productseach having a predetermined weight and volume. For example, the widthand length of the final product may be controlled to produce a producthaving a weight of one-ounce. Sausage patties may be produced by thesystem having a weight of from 11/2 to 5-ounces. If desired, the presentdevice may be utilized to produce square sausage patties having anydesired width to generate a specific weight. An important aspect of thepresent invention is that a very high degree of portion control may beachieved by the present system to provide products of uniform size,shape and weight. The emulsion density, emulsion flow speed, freezerbelt speed, the slicer operation and cutoff blade operation may bevaried in order to maintain the exact desired weight, or to change to adifferent desired weight or size. If desired, the width of one of thecontinuous lengths may be increased in order to produce one lane ofheavier lengths which may then be used to increase the weight of lightsausage packages.

The severed sausages formed by the cutter 26 unit are applied to aloader 28 which accumulates predetermined numbers of sausages andapplies them to a fill and seal station 30. The station 30 fills cartonswith predetermined numbers of frozen sausages and seals the cartons. Thecartons are then directed to a weighing station 32 and then to a metaldetector station 34. A plurality of cartons are loaded into cases atstations 36 and the cases are then sealed for transport.

The present hot molding process, in combination with the presentextrusion system, enables the production of packages of frozen porklengths or sausage patties within 70 to 90 minutes after live hogs enterthe restrainer in the slaughtering department. The present system canthus produce over 3,000 pounds an hour of sausage in a nonstop processwhich requires only a few workers for maintaining operation of themachine. With the addition of additional extruders, greater yields may,of course, be provided.

The present process is extremely economical, in that no storage space isnecessary, as the sausages may be packaged and loaded onto a truckwithin several hours of the time the hogs are slaughtered. The presentsystem is extremely accurate in the control of portions, as 16one-pounce lengths may be packaged to a package to provide a very closetolerance to a 1 pound meat package. The present system provides verylow waste, as there is no discard of bits and pieces, which occurs withprior techniques. The present system provides an increased yield, as themeat is not continuously handled after slaughter.

FIG. 2 illustrates in detail the extrusion system of the invention. Thesemi-fluid sausage material is applied from pump 16 through thedistribution line 18 to extrusion manifold 20. The extrusion manifoldhas a generally conical configuration at inlet 38 connected todistribution line 18. The manifold gradually flattens to a rectangularoutlet 40 which is joined to flexible conduit 22 having an identicalrectangular configuration for maintaining the semi-fluid material in theshape generated by passage of the fluid through the extrusion manifold.The cross-sectional area of the rectangular outlet of extrusion manifold20 is slightly smaller than that of the inlet end 38 connected todistribution line 18. In this way, a rectangular sheet 23 of semi-fluidmaterial extruded from manifold 20 is continuous without voids whichwould otherwise occur.

A metering pump 42 is interconnected between extrusion manifold 20 andflexible concuit 22 and is mounted on support brackets 44. Metering pump42 maintains the flow rate of material from extrusion manifold 20 intoconduit 22. Extrusion manifold 20 is supported by support 46. A base 47supports the support 46 and support brackets 44. Base 47 includes thedrive motor (not shown) for the metering pump 42.

An extrusion nozzle 48 is attached to the outlet end of conduit 22 andis received in a nozzle support housing 50. Nozzle support housing 50 ismounted on a parallelogram linkage including arms 52 and 54 which arepivotally joined by the horizontal bars 56. The parallelogram linkagemay be moved from the illustrated lower position to an upper position,to be subsequently described, in order to move nozzle 48 into and out ofcontact with a material conveyor 58. Conveyor 58 comprises a metal meshconveyor belt which conveys the extruded semi-fluid material intonitrogen freezer 24.

FIG. 2 further illustrates the pump of the present extruder. Semi-fluidmaterial is applied through a conduit 15 from the blenders 14a and 14b(FIG. 1) to pump 16. Pump 16 may comprise any suitable type of pump, schas a Crepaco auger feed pump with a de-aerating head, which may beoperated to force the semi-fluid material through the distribution line18 at a prescribed flow rate. A pressure gauge 59 communicates with thedistribution line 18 in order to enable pump 16 to be manually adjustedto maintain the desired pressure and flow rate. Semi-fluid materialflows through the distribution line 18 to extrusion manifold 20 in themanner previously described.

As previously described, rectangular outlet 40 is smaller in diameterthan inlet 38 to the manifold 20. Outlet 40 is connected to flexibleconduit 22 which leads to metering pump 42. Pump 16, distribution line18, extrusion manifold 20 and pump 42 are preferably comprised ofstainless steel for cleanliness of operation. Metering pump 42 iscommonly driven from a DC motor (not shown). The metering pump operatesto provide equal pressure, flow rate speed and consistency of thesemi-fluid material across extrusion nozzle 48. The head pressureapplied to metering pump 42 is greater than the output from the pump inorder to enable constant extrusion and to enable control of the densityand weight of the resulting emulsion extruded. For example, the headpressure applied to pump 42 may be 40 PSI, with the output pressure fromthe pump being 10 PSI. Nozzle 48 is particularly designed to provideeven extrusion distribution and to prevent uneven density throughout theextruded product.

FIG. 3 illustrates in greater detail extrusion manifold 20 used to moldthe semi-fluid material from the configuration defined by distributionline 18 to the continuous rectangular sheet of material extruded fromoutlet 40 of the manifold. Manifold 20 is provided with a generallyconical cross-sectional configuration at inlet 38. Inlet 38 includesthread 62 for threadedly receiving distribution line 18. The conical endof manifold 20 gradually flattens to become rectangular outlet 40opposite inlet 38. As previously noted, outlet 40 is connected toflexible conduit 22 by way of metering pump 42 as shown in FIG. 2.

Referring to FIG. 3, guide ribs 64 are provided on the inner surface ofmanifold 20 to guide the sausage material evenly from inlet 38 torectangular outlet 40 opposite thereto. These ribs assure the movementof the semi-fluid material to the full length of rectangular outlet 40of the manifold and eliminate any voids which might otherwise resultfrom the passage of the material through the manifold.

FIG. 4 shows a sectional view of manifold 20 in the intermediatetransition area between inlet 38 and outlet 40. Ribs 64 are shownextending from both the upper and lower walls of the manifold.

FIG. 5 illustrates the configuration of the extrusion manifold nearoutlet 40. At this point, ribs 64 are tapered away so as not tointerfere with the rectangular configuration discharged from themanifold. Thus, as the semi-fluid material passes out of the manifold,it takes the form of a relatively thin evenly distributed rectangularsheet of material.

FIG. 6 illustrates extrusion nozzle 48 which forms the continuous sheetof semi-fluid material to be delivered into freezer 24. Flexible conduit22 has been eliminated from FIG. 6 for clarity of illustration.Referring to FIG. 6, it will be seen that nozzle 48 slants downwardlytoward the metal mesh, endless belt conveyor 58 which travels intofreezer 24. Nozzle 48 is removably mounted in a housing 72, mounted onrod 74 to form the previously described nozzle support housing 50.

FIG. 7 illustrates in greater detail the interconnection of nozzle 48 torod 74. Rod 74 extends horizontally across the belt conveyor 58 and isattached at opposite ends to the parallel linkages comprising arms 52,54 and bar 56 (FIG. 6) previously described. Housing 72 is rigidlymounted along the rod 74.

Housing 72 includes two mating sections 72a and 72b interconnected bysuitable means such as bolts 80. The lower section 72a of housing 72 isprovided with a rectangular cutout along its entire upper length forreceiving nozzle 48 therein. Nozzle 48 includes an enlarged frontportion 48a for abutting with the front edge of lower section 72a andupper section 72b. Nozzle 48 includes a rearwardly extending portion 48bfor connection to flexible conduit 22. This rearwardly extending portionalso includes an enlarged section in order to facilitate a fluid-tightconnection to the flexible conduit. Therefore, by positioning nozzle 48within the rectangular cutout of housing 72 and assembling the uppersection 72b thereabove, nozzle 48 is securely attached within housing72.

Lower section 72a is further adapted with a circular bore 82 extendingalong its entire longitudinal length and below the rectangular cutoutprovided for nozzle 48. Bore 82 is adapted to receive rod 74 intofrictional engagement. In addition thereto, set screws 84 may beprovided for insertion through the lower side of housing 72 to engagerod 74 to maintain rod 74 fixed within housing 72 during operation.

When it is desired to clean the system, the upper portion of housing 72is simply removed by removing bolts 80 and releasing nozzle 48 forcleaning. All of the elements shown in FIG. 7 are made of stainlesssteel to facilitate cleaning.

As shown in FIG. 6, in operation of the invention, continuous sheet 23of semi-fluid material is extruded from nozzle 48. A stainless steelextrusion form 90 may be attached to conveyor 58 in order to guidecontinuous sheet 23 into the freezer while maintaining the sheet in theconfiguration in which it is extruded. Form 90 has a flat lower surface90a and upright side members 90b to prevent the semi-fluid material fromspreading out of its extruded configuration prior to chilling. Form 90also facilitates the subsequent step of slicing the material as willhereinafter be described.

Alternatively, conveyor 58 may be adapted with vertical side memberscorresponding to the edges of the extruded continuous sheet of material.In this embodiment, the extruded material is deposited directly on thebelt conveyor and carried into freezer 24.

Referring to FIG. 6, conveyor 58 is moving at the same speed ascontinuous sheet 23 is being extruded or in the preferred embodiment, atapproximately 15 feet per minute. Similarly, form 90, where used, movesat the same speed as belt conveyor 58. The extruded continuous sheet 23is promptly moved by conveyor belt 58 into the nitrogen freezer 24(FIG. 1) whereupon the continuous sheet is immediately chilled to anextent that it maintains its cross-sectional shape. The present processis carried out in a room having an ambient room temperature ofapproximately 50° F. The freezer is provided with a temperature ofapproximately -170° F. in order to chill the interior of continuoussheet 23 to approximately -10° F. Nitrogen or fluorocarbon liquid may besprayed on the sausage or underneath the conveyor in order to quicklychill the sausage.

When the system is initially turned on for operation, continuous sheet23 initially extruded may not be of a desired consistency or at thedesired flow rate. Thus, a handle 98 is provided on the parallelogramlinkage comprised of arms 52, 54 and bar 56 in order to enable nozzle 48to be raised away from contact with conveyor 58. Referring to FIG. 9,the dotted line position illustrates the upward position of nozzle 48when in the raised position. In this position, the extruded material maybe extruded into a dump bucket (not shown), until the material reachesthe desired consistency or flow rate. At such time, the dump bucket maybe removed and the parallelogram linkage moved downwardly by graspinghandle 98 and pushing downwardly until nozzle 48 is again oriented atthe desired angle to the conveyor as shown in FIG. 6.

Referring to FIG. 10, slicer 25 and cutter unit 26 of the invention areillustrated in detail. As previously noted, cutter unit 26 is located atthe output of freezer 24 which delivers the continuous sheet 23 ofchilled pork sausage to the cutter unit. Chilled sheet 23 is directed toextrusion form 90 which includes base 90a and vertical sides 90bcorresponding to the width of the continuous sheet. The sheet is thusguided past a plurality of vertically suspended rotatable cutting disks102 where the sheet is sliced into a plurality of equal width continuouslengths 104 of chilled material. Lengths 104 are then carried byconveyor 58 to an elongated vertical knife blade 106 which isreciprocated in a manner to be subsequently described in synchronismwith a horizontal bed 108. A hold-down roller 110 is disposed in frontof blade 106 in order to hold the continuous links down during thesevering operation by knife blade 106. A back board 112 is disposed overblade 106.

As indicated above, slicing of the continuous sheet 23 into a pluralityof equal width continuous lengths 104 is accomplished by the action ofrotatable cutting disks 102. As shown in FIG. 11, disks 102 arerotatably assembled along horizontal bar 116. The ends of bar 116 arefixedly supported by a sleeve support member 118 which slidingly engagesupper rod 120. Sleeve member 118 is adapted with a collar 122 and rod120 is adapted with a corresponding flange 124 to permit limitedtranslation of sleeve 118 along rod 120. A compression spring 126 isassembled between the lower end of rod 120 and a seat 118a provided atthe lower end of sleeve support member 118. Compression spring 126 actsagainst rod 120 to apply a downward force upon rod 116 and thus engagecutting disks 102 against the chilled sausage material passing belowdisk 102. Rod 120 is rigidly supported from arms 130 which extend from asuitable frame structure 132. An identical connection exists between bar116 and frame structure 132 on the opposite end of bar 116. In this way,the cutting disks 102 are kept in proper slicing engagement against thechilled sausage material moving on conveyor 58.

As is seen in FIG. 11, form 90 is adapted with longitudinal indentions134 which correspond with the cutting edge of cutting disk 102. Thesesmall indentions facilitate severing of the chilled sausage materialinto continuous lengths. Vertical sides 90b of form 90 can also be seento prohibit the lateral flow of sausage material during cutting. FIG. 11further illustrates the action of compression springs 126 against bar116 in order to engage cutting disks 102 against the sausage material.Likewise, the compression springs may be adapted with an adjustment forselectively increasing or decreasing the force applied to cutting disks102 as necessary to effect a proper cut.

Referring to FIG. 12, bed 108 reciprocates in a horizontal plane overrollers 142 and 144. The cutting assembly is mounted on a horizontalplatform 146 supported by legs 148. The reciprocating movement of knifeblade 106 and bed 108 is provided by an electrical motor 150 whichoperates a drive motor 152. The output shaft of motor 152 rotates a gear154 which operates a timing belt 156. Belt 156 operates a gear 158 of alinear displacement cam 160.

The output shaft of the motor 152 also rotates a gear 162 which operatesa timing belt 164. Belt 164 rotates a gear 166 attached to a secondlinear displacement cam 168. The output of motor 152 also rotates a gear170 which moves a timing belt 172 which rotates a gear 174 of a thirdlinear displacement cam 176. The three linear displacement cams 160, 168and 176 operate in the known manner to translate rotary motion to linearmotion. Suitable linear displacement cams are manufactured and sold bythe Stelron Corporation.

A block 180 is mounted above the linear displacement cam 168, while ablock 182 is mounted above the cam 176. A vertical post 184 is pivotallymounted at pivot point 186 to block 180. Similarly, a vertical post 188is pivotally mounted at pivot point 190 to block 182. The tops of posts184 and 188 are connected to blade 106. Operation of the lineardisplacement cams 168 and 176 thus serve to provide vertical movement toblade 106. Operation of the linear displacement cam 160 operates toprovide horizontal reciprocational movement to the cutting blade 106 andbed 108.

The back board 112 is shown interconnected with knife blade 106. Posts188 and 184 operate to provide vertical movement to knife blade 106 inorder to sever the continuous lengths of sausage in the manner to besubsequently described. The bed 108 rides upon rollers 142 and 144 inthe manner previously described. A rod 200 includes a plurality ofrollers 202 thereon in order to hold the continuous lengths down duringthe cutting operation.

As previously noted, the linear displacement cams 168 and 176 operate tocause reciprocating vertical motion to the posts 184 and 188. Knifeblade 106 is attached to the top of posts 184 and 188 by bolts 220 (notshown) and 222 such that blade 106 is moved up and down in order to cutthe continuous lengths. Inasmuch as the continuous lengths are travelingperpendicular to the orientation of blade 106, blade 106 cuts each ofthe continuous lengths simultaneously.

Linear displacement cam 160 reciprocates a block 224 in a horizontalplane. Block 224 is attached by arms 226 and 228 to posts 184 and 188.Thus, arms 226 and 228 are moved horizontally, thereby causing the posts184 and 188 to pivot about pivot points 186 and 190. The posts 184 and188 thus swing back and forth in a limited arc in order to move knifeblade 106 in a horizontal plane. This mechanism also causes the movementof the bed 108 on a horizontal plane.

It will be seen from FIG. 12 that the posts 184 and 188 and the arms 226and 228 may be selectively adjusted to any of several desired positionsin order to allow the movement of blade 106 and bed 108 to beselectively adjusted. In this manner, the length of cuts made by thecutting blade may be selectively adjusted in order to enable the weightof the final discrete product to be selectively adjusted.

FIGS. 13a-13d illustrate the cutting operation of blade 106 and bed 108.Referring to FIG. 13a, blade 106 is shown in its initial startingposition just behind roller 142 which operates to maintain continuouslength 104 against bed 108. During operation of the device, knife blade106 covers a reciprocating path indicated by the dotted line 234. Thatis, knife 106 moves along with length 104 for a short distance and isthen moved downwardly in order to sever length 104. Subsequently, knifeblade 106 is moved upwardly and is then raised and moved to the originalstarting position shown in FIG. 13a. Roller 142 rotates in the directionillustrated during operation of blade 106.

FIG. 13b illustrates how the knife blade 106 has been moved to the rightin synchronism with movement of bed 108 and then moves downwardly inorder to sever length 104. Inasmuch as blade 106 and bed 108 aretraveling at the same rate as the length 104, the lengths do not have tobe stopped to enable severing thereof.

FIG. 13c illustrates the final severing of length 104. As shown in FIG.13c, bed 108 includes a depression 236 which receives the foremost edgeof blade 106 in order to insure that the blade passes completely throughlength 104. Moreover, FIG. 13c illustrates the particular shape of knifeblade 106. The lower-most portion 238 of the blade is relatively narrowand is maintained with a very sharp lower point. The upper portion 240of the blade is wider than the lower portion. The two portions areseparated by a beveled portion 242. The lower portion 238 is thusutilized to make the initial cut through length 104. The upper and widerportion 242 acts to push the severed portion of length 104 away from theuncut portion, and thus tends to break and completely sever any fiberswhich would tend to prevent clean cutting.

After the blade has made its downward descent as shown in FIG. 13c, theblade is raised while still traveling in the direction and at the samerate as length 104 until it reaches the position shown in FIG. 13d. Atthis position, blade 106 and bed 108 change horizontal direction andmove back to the original starting point as shown in FIG. 13a. As shownby the arrow 246, continuous length 104 has thus been severed by theknife blade 106. The blade 106 is continuously moved in the path shownby the dotted line 234 in order to periodically cut off identicallengths of product. In this way, products of exact weight, volume andconsistency may be maintained. If desired, the volume, consistency, flowrate or length of cutting path of blade 106 may be varied in order tochange the volume or weight or consistency of the final product. For amore detailed description of the operation of knife blade 106 and bed108, during severing of continuous length 104, reference can be made tocopending application, Ser. No. 610,301, filed Sept. 4, 1975, which isincorporated herein by reference.

FIG. 14 illustrates the output at cutter unit 26 which operates in themanner previously described. A downwardly sloping dispensing surface 260extends from the output of the cutter unit and a plurality of discretesausage lengths 262 may be seen to be dispensed from cutter unit 26. Theproducts 262 roll and slide downwardly to a conveyor 264 whereuponproducts are conveyed to loading station 28.

As previously noted, a particular advantage to the present invention isthat very accurate portion control may be provided for the presentproducts. Thus, each of the products 262 may be formed with the samevolume and size and weight so that a discrete number of the products maybe packaged in individual cartons. For example, each of the products 262may be cut to weigh one-ounce, and thus sixteen one-ounce products maybe packaged together to provide a one-pound package. With the use of thepresent invention, a very accurate weight is maintained with eachproduct. However, if the weight is desired to be changed, the system maybe easily varied to change the weight. The product 262 is already frozenwhen packaged, and thus additional hard freezing is not required afterpacking.

FIG. 15 illustrates another embodiment of the cutter unit. A continuoussheet 270, having a rectangular cross-section, is illustrated as havingbeen extruded and then chilled as previously described. The sheet isapplied through a cutting station which includes a rotating cutting drum272 including a cylindrical drum 273 having a plurality of slicing disks274 equally spaced along a longitudinal length thereof and a pluralityof equally spaced cutting blades 276 along the longitudinal lengththereof. The cutting drum 272 is rotatably supported on axis rod 278which is supported in a fashion similar to the support and springstructure defined with respect to the cutting disks illustrates anddescribed with respect to FIG. 10. Thus, cutting drum 272 is engagedagainst the continuous sheet of chilled material which passes beneaththe cutting drum as it is carried by the belt conveyor 58. The pressureof the cutting drum against the sheet of chilled material results in thesevering of a plurality of rectangular products 280 which are thencarried on the conveyor to a packaging station.

FIG. 16 illustrates a cross-sectional view taken along a vertical planethrough the longitudinal axis of cutting drum 272. In this embodiment ofthe invention, belt conveyor 58 is provided with a plurality oflongitudinal indentions 282 corresponding to the cutting edges of theslicing disks 274 in order to facilitate the complete severing of thechilled pork sausage. Similarly, the conveyor surface may likewise beadapted with transverse indentions 284 corresponding to the longitudinalcutting blades 276 extending longitudinally along cutting drum 272 (FIG.15). In this case, the rotation of the cutting drum must be synchronizedwith the movement of conveyor 58 in order that longitudinal blades 276mate with transverse indentions 284.

FIG. 17 illustrates another embodiment of the severing device used inthe present invention. Again, a continuous sheet 270 of chilled sausagematerial is illustrated as it moves on conveyor 58 from freezer 24. Thecontinuous sheet of chilled material is carried on conveyor 58 through acutting station which includes a dual conveyor system for stampingdiscrete predetermined shapes of sausage material and carrying thesevered shapes to an appropriate packaging station.

The first conveyor system includes an endless conveyor 300 entrained forcontinuous movement around drums 302 and 304 which are powered by anappropriate power means, such as an electric motor (not shown). Conveyor300 has its longitudinal axis aligned with the longitudinal axis ofmaterial conveyor 58 and is positioned for rotation directly aboveconveyor 58, but having an opposite rotational direction. Conveyor 300is adapted with a plurality of annular chambers extending the full widthof the conveyor, such as chamber 300a, between its inner and outersurfaces. A plurality of stamping modules 306 extend perpendicularlyfrom the outer surface of conveyor 300 and communicate with one of theannular chambers as hereinafter described.

Stamping modules 306 are adapted with a cutting configuration having acylindrical or other desired shaped face 308 and corresponding cuttingsidewall 309 extending therefrom to form a cup-like cutting unit 310. Atubular shaft 312 is connected to the outer surface of face 308 and isjoined to conveyor 300 by way of an actuator valve 314 which is capableof extending the cutting module in response to a predetermined signalapplied thereto. Tubular shaft 312 also communicates with one of theannular chambers between the inner and outer surfaces of conveyor 300. Asecond conveyor 320 is rotatable about motorized drums 322 and 324 (notshown). Conveyor 320 has its longitudinal axis transverse to the axes ofconveyors 58 and 300 with its upper path of travel between conveyors 58and 300.

FIG. 18 illustrates a cross-sectional view taken along the longitudinalaxis of conveyor 320 and showing the relationship of the stampingmodules 306 with respect to the material conveyor 58 and conveyor 320.In operation of the unit, belt conveyor 300 is moved at a rate of speedequal to the speed of travel of conveyor 58 on which the continuoussheet of chilled pork sausage is carried. A predetermined signal isapplied to selected rows of actuator valves 314 attached to each of thecutting units 310 as conveyor 300 moves over a predetermined point ofits course. While not so limited, the signal may be an electrical signalcommunicated to a selected number of rows of stamping modules 306 as therows pass an electrical connection.

Referring to FIGS. 19a-19c, in response to the signal, tubular shaft 312is extended, forcing the stamping module 306 against the chilled sausagematerial. The action of the cutting sidewall 309 against the chilledmaterial results in the severence of a discrete portion of the materialin the configuration defined by the cutting unit 310 (FIG. 19b).Simultaneously therewith, annular chamber 300a moves into communicationwith a vacuum line 316 connected to an appropriate vacuum drawing system(not shown) for applying suction through each cutting unit 310communicating with annular chamber 300a. This suction creates a vacuumto facilitate the withdrawal of the sausage material with the cuttingunit. The cutting units 310 are withdrawn from the sheet of sausage(FIG. 19c) conveyor 300 moves past the point at which the predeterminedsignal is communicated to actuator valves 314. It will be understoodthat the extension of the cutting units is carried out by simultaneouslyactuating a group of cutting units such that one area of the continuoussheet is stamped at one time. The cycle is repeated sequentially withrespect to successive groups of units as they pass over the sheet ofsausage material.

After withdrawal of the cutting units 310, the cutting units pass abovetransverse conveyor 320 which is continuously rotating therebelow. Itwill be noted that the cutting heads normal retracted position is asufficient distance above material conveyor 58 such that the heads areabove transverse conveyor 320 which passes above material conveyor 58.As the cutting units pass above transverse conveyor 320, annular chamber300a moves out of communication with the vacuum source. Thus, the vacuumdrawn above the severed material is removed and the discrete sausageproducts contained therein are ejected onto belt conveyor 320. It may befound benefical in some instances to apply air pressure against the backside of the severed material retained in the cutting units by applying apositive pressure through annular chamber 300a in order to assure thedischarge of the discrete sausage products contained therein ontoconveyor 320. The discharge of the discrete products onto the transverseconveyor 320 is accomplished without the interruption of the movement ofthe cutting units on conveyor 300. The cutting units continue to moveabout conveyor belt 300 and the process of stamping discrete sausageproducts from the continuous chilled material sheet 270 is continued onan uninterrupted basis.

It will be noticed that the cutting units 310 are closely positioned soas to minimize materials which are not severed in the stamping process.Where rectangular configurations are stamped from the continuous sheetof chilled material, the sausage material not cut by the stamping unitswill be minimized or eliminated altogether. Where a circular or otherirregular design is desired, the sausage material not stamped by thecutting units 310 is recycled and fed back through extrusion manifold 20(FIG. 1).

The discrete sausage products discharged onto conveyor 330 are carriedon the conveyor to an appropriate packaging station where the productsare packaged in desired quantities. It will be appreciated that in theabove described embodiment, the severing and discharge steps are carriedout without interrupting the movement of the cutter units on conveyor300 or the conveyors 58 or 320.

As previously mentioned, although the present invention has beendescribed with respect to preparing chilled pork sausage, it will beunderstood that the present apparatus and method may be utilized toproduce a wide variety of products when it is desired to form aplurality of discrete products having the same weight, size andcharacteristics from a semi-fluid material.

Whereas the present invention has been described with respect tospecific embodiments thereof, it will be understood that various changesand modifications will be suggested to one skilled in the art, and it isintended to encompass such changes and modifications as fall within thescope of the appended claims.

What is claimed is:
 1. A system for forming a plurality of discreteproducts having preselected volumes and weights comprising:means forreceiving a quantity of semi-fluid material, a pump for pumping saidmaterial at a selected rate, an extruder associated with said pump andhaving an inlet to receive said pumped material and having an outlet foroutputting said pumped material, conduits connected to said outlet forconveying a continuous uniform thickness sheet of said material, achilling station located at the remote end of said conduit for receivingsaid continuous sheet of said material and for chilling said continuoussheet to an extent that said sheet maintains its extruded cross-section,a plurality of equally spaced parallel rotatable cutting disks locatedat the outlet of said chilling station for continuously slicing saidchilled sheet into continuous lengths and means for periodicallysevering the continuous lengths to form a plurality of products havingthe preselected volume and weight, said means for severing including anelongated cutting blade disposed above and normal or said continuouslengths, and means for moving said blade downwardly for simultaneouslysevering all of said continuous lengths while moving said blade in thedirection of travel of said continuous lengths and at the same speed oftravel of said continuous lengths.
 2. The system of claim 1 wherein saidchilling station comprises:a chamber defining a linear chilling path, aconveyor extending through said chamber for carrying said continuoussheet along the linear chilling path at the same rate as said continuoussheet is extruded, and freezer means for lowering the temperature insaid chamber such that the semi-fluid material passing therethrough isfrozen.
 3. A system for forming a plurality of discrete products havingpreselected weights comprising:a hopper for receiving a quantity of warmsemi-fluid material, a feed line, a pump for pumping said materialthrough said feed line at a selected rate and pressure, an extrudermanifold having an inlet connected at the end of said feed line andincluding an outlet with a smaller dimension than said inlet, a flexibleconduit extending from said manifold outlet and including an end nozzleto form a continuous extruded sheet of material, a metering pump mountedin series with said flexible conduit to meter the flow of said materialtherethrough, a chilling chamber mounted adjacent said end nozzle, aconveyor for receiving said continuous sheet from said end nozzle andfor carrying said continuous sheet through said chilling chamber tochill and firm said continuous sheet, a plurality of rotatable slicingdisks, each said disk having a cutting edge along the circumferencethereof and mounted at the outlet of said chilling chamber for slicingsaid continuous sheet into parallel continuous lengths of equal widths,and a cutting blade mounted downstream of said slicing disks and movablein synchronism with said conveyor for severing said continuous lengthsto form a plurality of discrete products having the selected weight. 4.The system of claim 3 wherein said semi-fluid materialcomprises:pre-rigor pork sausage having a temperature of at least 80° F.5. The system of claim 3 wherein said chilling chamber is chilled bynitrogen.
 6. The system of claim 3 wherein said conveyor conveys saidcontinuous lengths along a linear path at the same rate as saidcontinuous sheet is extruded.
 7. The system of claim 3 wherein saidextruder manifold comprises:a housing having a cone shaped end with saidinlet connected in the region of the apex of the cone and a rectangularend with said outlet disposed therein for extruding a rectangular sheetof said semi-fluid material.
 8. The system of claim 3 wherein said endnozzle is mounted along an elongated housing and oriented downwardlytowards said conveyor, andmeans for attaching said nozzle to saidelongated housing.
 9. The system of claim 8 and further comprising:meansoperable to raise and lower said end nozzle out of and into orientationwith said conveyor.
 10. The system of claim 3 and furthercomprising:guide means associated with said conveyor for maintaining thecross-sectional shape of said continuous sheet until said continuoussheet is chilled.
 11. The system of claim 3 wherein said conveyor isadapted with longitudinal indentions corresponding to the cutting edgesof said slicing disks for facilitating the slicing of said continuoussheet.